PROCESS AND APPARATUS FOR THE PRODUCTION OF A MEAT ANALOGUE

Abstract

The present invention relates to a process for the production of a meat analogue, comprising: a) introducing a meat batter which comprises protein into a first heating unit and heating the meat batter to a temperature above the denaturation temperature of the protein in the meat batter, but below the melting point of the protein to produce a first heat-treated product, and b) transferring the first heat-treated product to a second heating unit and heating the first heat-treated product to a temperature above the melting temperature of the protein to produce a second heat-treated product, c) cooling the second heat-treated product by moving through a cooling unit, so that the second heat-treated product has a temperature below water boiling temperature at ambient pressure when exiting the cooling unit, and d) dividing the cooled second heat-treated product into pieces; as well as to an apparatus for the production of a meat analogue.

Claims

1. A process for the production of a meat analogue, comprising: a) introducing a meat batter which comprises protein into a first heating unit and heating the meat batter to a temperature above the denaturation temperature of the protein in the meat batter, but below the melting point of the protein to produce a first heat-treated product, and b) transferring the first heat-treated product to a second heating unit and heating the first heat-treated product to a temperature above the melting temperature of the protein to produce a second heat-treated product, c) cooling the second heat-treated product by moving through a cooling unit, so that the second heat-treated product has a temperature below water boiling temperature at ambient pressure when exiting the cooling unit, and d) dividing the cooled second heat-treated product into pieces.

2. The process according to claim 1, wherein at least one of the first and second heating units comprises a scraped surface heat exchanger.

3. The process according to claim 1, wherein the first and second heating units both comprise a scraped surface heat exchanger.

4. The process according to claim 1, wherein the meat emulsion is heated in the first heating unit to a temperature of about 90 C. to about 120 C.

5. The process according to claim 1, wherein the first heat-treated product is heated in the second heating unit to a temperature of about 140 C. to about 170 C.

6. The process according to claim 1, wherein the ratio of residence time of the meat emulsion in the first heating unit to the residence time in the second heating unit is from about 3:2 to about 14:2, preferably from about 3:2 to about 7:2.

7. The process according to claim 1, wherein the pressure in the first heating unit is about 800 to about 2000 kPa, and/or the pressure in the second heating unit is about 800 to about 2000 kPa.

8. The process according to claim 1, wherein the protein comprises an animal protein, a non-animal protein or a mixture thereof.

9. An apparatus for the production of a meat analogue comprising: i) a first heating unit, ii) a first transfer means for transferring a meat batter which comprises protein into the first heating unit, the first heating unit being operable to be heated to a temperature above the denaturation temperature of the protein but below the melting temperature of the protein, iii) a second heating unit being operable to heat a first heat-treated product obtained from the first heating unit to a temperature above the melting temperature of the protein in the first heat-treated product, wherein the first heating unit and the second heating unit are arranged in series, iv) a cooling unit located downstream the second heating unit and operable to cool down a second heat-treated product obtained from the second heating unit below water boiling temperature at ambient pressure when exiting the cooling unit, and v) a dividing unit located downstream the cooling unit suitable for dividing cooled down second heat-treated product obtained from the cooling unit into pieces.

10. The apparatus according to claim 9 additionally comprising one or more of: i) a grinder, ii) a mixer, iii) an emulsifying unit or an emulsion pump installed upstream of the first transfer means, iv) a conditioning unit, v) a packaging unit,. vi) a sterilization unit installed downstream of the second heating unit.

Description

EXAMPLES

Example 1

[0049] Three parts of a slurry containing 90.8% meat and animal derivatives, 4.7% water, and 4.5% of at least one of vitamins, minerals, palatants, colorants, etc. (all percentages are weight percentages based on the total weight of the slurry) as to achieve a nutritionally complete cat food finished product were mixed with one part vegetable protein powder containing at least 75% protein (vital wheat gluten) to form a semisolid mixture containing 30.5% crude protein, 59% moisture and 4.5% fat (all percentages of the semisolid mixture are based on the total weight of the semisolid mixture).

[0050] The mixture was fed into a first SSHE unit with a volume of approx. 17 L and a surface to volume ratio of 60 m.sup.2/m.sup.3 under 1,200 kPa product pressure. The first SSHE unit was continuously supplied with steam at a temperature between 134-136 C. and the shaft operated at 200 rpm. The outlet temperature of the material from this heating unit was between 109 C. and 111 C. The material was immediately directed into a second SSHE unit with a volume of approx. 9.7 L and a surface to volume ratio of 60 m.sup.2/m.sup.3 under 1,200 kPa product pressure. The second SSHE unit was continuously supplied with steam at a temperature between 166 C.-168 C. and the shaft operated at 300 rpm. The outlet temperature of the material from this heating unit was between 158 C.-160 C. The residence time in the two heating units was distributed as two-thirds in the first heating unit and one third in the second heating unit. The material was then directed to a cooling area through which its temperature was brought down to below 80 C. The solid material obtained was cut to produce meat analogues with internal fibrosity.

Comparative Example 2

[0051] Three parts of meat emulsion containing 90.8% meat and animal derivatives, 4.7% water, and 4.5% of at least one of vitamins, minerals, palatants, colorants, etc. (all percentages are weight percentages based on the total weight of the slurry)as to achieve a nutritionally complete cat food finished product were mixed with one part vegetable protein powder containing at least 75% protein (vital wheat gluten) to form a semisolid mixture containing 30.5% crude protein, 59% moisture and 4.5% fat (all percentages of the semisolid mixture are based on the total weight of the semisolid mixture).

[0052] The mixture was fed into a SSHE unit with a volume of approx. 14.6 L and a surface to volume ratio of 60 m.sup.2/m.sup.3 under 1,200 kPa product pressure. The SSHE unit was continuously supplied with steam at a temperature between 166 C.-168 C. and the shaft operated at 300 rpm. The outlet temperature of the material from this heating unit was between 158 C.-160 C.

[0053] The material was then directed to a cooling area through which its temperature was brought down to below 80 C. The solid material obtained was cut to produce meat analogues with internal fibrosity.

[0054] A comparison of food intake by cats between the product manufactured using two SSHEs and the product manufactured using one SSHE showed cats eating on average 21% less (weight) from the product manufactured using a single SSHE, a statistically significant loss under conditions tested.

Comparative Example 3

[0055] Three parts of meat emulsion containing 90.8% meat and animal derivatives, 4.7% water, and 4.5% of at least one of vitamins, minerals, palatants, colorants, etc. (all percentages are weight percentages based on the total weight of the slurry) as to achieve a nutritionally complete cat food finished product were mixed with one part vegetable protein powder containing at least 75% protein (vital wheat gluten) to form a semisolid mixture containing 30.5% crude protein, 59% moisture and 4.5% fat (all percentages of the semisolid mixture are based on the total weight of the semisolid mixture).

[0056] The mixture was fed into a first SSHE unit with a volume of approx. 17 L and a surface to volume ratio of 60 m.sup.2/m.sup.3 under 1,200 kPa product pressure. The first SSHE unit was continuously supplied with steam at a temperature between 120 C.-125 C. and the shaft operated at 200 rpm. The outlet temperature of the material from this heating unit was below coagulation temperature and between 60 C. and 70 C. The material was immediately directed into a second SSHE unit with a volume of approx. 9.7 L and a surface to volume ratio of 60 m.sup.2/m.sup.3 under 1,200 kPa product pressure. The second SSHE unit was continuously supplied with steam at a temperature between 120 C.-125 C. and the shaft operated at 200 rpm. The outlet temperature of the material from this heating unit was below melting temperature and between 80 C.-85 C. The residence time in the two heating units was distributed as two-thirds in the first heating unit and one third in the second heating unit. The material was then directed to a cooling area through which its temperature was brought down to below 80 C.

[0057] No internal fibrosity was observed in the outlet material, only protein coagulation.

Comparative Example 4

[0058] Three parts of meat emulsion containing 90.8% meat and animal derivatives, 4.7% water, and 4.5% of at least one of vitamins, minerals, palatants, colorants, etc. (all percentages are weight percentages based on the total weight of the slurry) as to achieve a nutritionally complete cat food finished product were mixed with one part vegetable protein powder containing at least 75% protein (vital wheat gluten) to form a semisolid mixture containing 30.5% crude protein, 59% moisture and 4.5% fat (all percentages of the semisolid mixture are based on the total weight of the semisolid mixture).

[0059] The mixture was fed into a first SSHE unit with a volume of approx. 17 L and a surface to volume ratio of 60 m.sup.2/m.sup.3 under 1,200 kPa product pressure. The first SSHE unit was continuously supplied with steam at a temperature between 134 C.-136 C. and the shaft operated at 200 rpm. The outlet temperature of the material from this heating unit was between 90 C. and 95 C. The material was immediately directed into a second SSHE unit with a volume of approximately 9.7 L and a surface to volume ratio of 60 m.sup.2m.sup.3 under 1,200 kPa product pressure. The second SSHE unit was continuously supplied with steam at a temperature between 166 C.-168 C. and the shaft operated at 250 rpm. The outlet temperature of the material from this heating unit was below melting temperature and between 120 C.-125 C. The residence time in the two heating units was distributed as two-thirds in the first heating unit and one third in the second heating unit. The material was then directed to a cooling area through which its temperature was brought down to below 80 C.

[0060] No internal fibrosity was observed in the outlet material, only protein coagulation.

[0061] The features disclosed in the foregoing description and in the claims may, both separately and in any combination, be material for realizing the invention in diverse forms thereof.